Turbocharger Vacuum Diaphragm, Adjusting

WARNING: This page is about a different variant/trim than selected.

Special tools and workshop equipment required

Pressure Control Valve VAS 6342
Dial Gauge Set, 4 Part VAS 6341
Hand Vacuum Pump VAS 6213
Turbocharger Tester V.A.G 1397 A
Dial Gauge Holder VW 387

NOTE:

This procedure adjusts the vacuum diaphragm. The values may differ when testing a vacuum diaphragm that has already been adjusted.

The vacuum diaphragm must be adjusted only if the linkage was loosened.

Adjustment is performed only with the turbocharger removed.

-- Disconnect the hose -arrow- from the vacuum diaphragm.

Fig 1: Disconnecting Hose From Vacuum Diaphragm At Turbocharger

GWWA21-10121

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Loosen the clip above the linkage on the turbocharger.

-- Loosen the lock nut -2-.

Fig 2: Identifying Lock Nut, Turbocharger, Vacuum Diaphragm

GWWA21-10124

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Adjust the bypass flap -1- above the vacuum diaphragm linkage -arrow- so the bypass flap can still be turned by hand.

Fig 3: Pre-Adjusting Bypass Flap Above Linkage Of Vacuum Diaphragm

GWWA21-10122

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Tighten the lock nut by hand.

-- Connect the hand vacuum pump VAS 6213, turbocharger tester V.A.G 1397 A and the pressure control valve VAS 6342 to the connection as shown in the illustration.

Fig 4: Connecting Hand Vacuum Pump VAS 6213, Turbocharger Tester V.A.G 1397A To Connection II And Pressure Regulator Valve VAS 6342

GWWA21-10120

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Close the pressure control valve VAS 6342 using the lever -1-.

-- Set the slide ring -1- on the hand vacuum pump VAS 6213 to position -B- for "pressure".

Fig 5: Setting Slide Ring On Hand Vacuum Pump VAS 6213 To Position For "Pressure"

GWWN24-10282

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Turn on the turbocharger tester V.A.G 1397 A and set the slide switch to position II.

-- Secure the dial gauge holder VW 387 onto the turbocharger -arrow-.

Fig 6: Securing Dial Gauge VAS 6341/1 With 30 mm Extension VAS 6341/3 And Level Tester VAS 6341/4 On Universal Dial Gauge Holder VW 387

GWWA21-10123

Courtesy of VOLKSWAGEN UNITED STATES, INC.

-- Secure the dial gauge 0-30 mm VAS 6341/1 with the dial gauge extension 30 mm VAS 6341/3 and the flat pickup VAS 6341/4 on the dial gauge holder VW 387.

-- Set the dial gauge 0-30 mm VAS 6341/1 to 0 bar with a 1 mm preload.

-- Rotate the indicator on the dial gauge 0-30 mm VAS 6341/1 to 0.

-- Check the dial indicator for ease of movement.

-- Operate the hand vacuum pump VAS 6213 until the turbocharger tester V.A.G 1397 A displays 350 +/-5 mbar.

-- The dial gauge must display 4.1 mm to 4.3 mm, otherwise rotate the linkage of the vacuum diaphragm until the value is displayed.

-- Tighten the lock nut by hand.

-- Repeat the measurement.

NOTE:

The mm specification apply to the value read out (includes the 1 mm preload).

-- Release the pressure via the pressure control valve VAS 6342 to 0 mbar.

-- Set the dial gauge 0-30 mm VAS 6341/1 to 0.

NOTE:

The following measurements must be performed in one sequence. In the meantime, the pressure must not dissipate to 0.

-- Operate the hand vacuum pump VAS 6213 until the turbocharger tester V.A.G 1397 A displays 350 +/-5 mbar.

-- Read and make a note of the value on the dial gauge 0-30 mmVAS 6341/1.

-- Operate the hand vacuum pump VAS 6213 until the turbocharger tester V.A.G 1397 A displays 650 to 700 mbar.

-- Release the pressure via the pressure control valve VAS 6342 to 350 +/- 5 mbar.

-- Read and make a note of the value on the dial gauge 0-30 mm VAS 6341/1.

-- Add values 1 and 2 and divide by 2.

-- The result (mean value) must be 5 +/- 0.25 mm.

-- If the result (mean value) is not 5 +/- 0.25 mm, correct the adjustment, tighten the lock nut by hand and repeat the measurement.

-- If the result (mean value) is 5 +/- 0.25 mm, tighten the lock nut to 5 Nm and secure it with sealing wax.

-- Secure the securing plate above the linkage of the vacuum diaphragm.